VRB Cantilever-Based Unloader Brace Assembly

ABSTRACT

An Unloader assembly to control load distribution about a joint is disclosed. The assembly comprises an upper collar attachable above the joint and a lower collar attached below the joint, and a hinge positioned between the upper attachment and the lower attachment. The Unloader further including a compression assembly includes an arm attached at one end to the hinge and a housing into which the arm is slidable. The housing further including a bushing and a variable resistance beam positioned between the arm and the bushing. The variable resistance beam provides a variable degree of rigidity to provide different levels of resistance to compression.

CLAIM OF PRIORITY

This application claims,

pursuant to 35 USC 119, priority to and the benefit of the earlier filing date of that patent application entitled:

“Exo-Unloader Knee Brace,” filed on Sep. 19, 2013 and afforded Ser. No. 61/880,147; and claims,

pursuant to 35 USC 119, priority to and the benefit of the earlier filing date of that patent application entitled:

“Methods for Adjusting Stiffness and Flexibility in Medical Braces, Devices, Apparatus and Equipment,” filed on Apr. 29, 2014 and afforded Ser. No. 61/986007; and claims,

pursuant to 35 USC 120, as a continuation-in-part, priority to and the benefit of the earlier filing date of that patent application entitled:

“Methods for Adjusting Stiffness and Flexibility in Devices, Apparatus and Equipment,” filed on Sep. 18, 2012 and afforded Ser. No. 13/622,331,

which claimed,

pursuant to 35 USC 119, priority to and the benefit of the earlier filing date of than patent application entitled:

“Exercise Apparatus Having a Resilient Solid Beam with Geometric Protrusions on the Outside for Adjusting Resistance and Stiffness,” filed on Jan. 11, 2012 and afforded Ser. No. 61/585,315, the contents of all of which are incorporated, in their entirety, by reference herein.

FIELD OF THE INVENTION

This application relates to the field of an exoskeleton device and more particularly to an exoskeleton unloader brace assembly.

BACKGROUND OF THE INVENTION

Medical braces are commonly used to support joints, e.g., elbows, knees, ankles, etc., either to protect the joint during strenuous activities or to provide support when the joint has been injured and is healing. Sports braces are commonly used to support joints when participating in athletic activities.

One type of brace is a simple bandage that wraps around the joint, applying a compression force around the joint. Another type of brace is an exoskeleton that locks the joint in a particular configuration.

The exoskeleton type knee brace, which is typically attached between a thigh and a calf, is commonly used to support the body's weight and maintain the intervening knee in a fixed plane of articulation, with the principle axial bend registered below the medial and lateral condyle of the femur. The brace distributes the user's weight around the knee so that the intervening knee is relieved of the pressure that is placed on it by the user's weight. By removing the pressure of the user's weight from the knee, further damage to the knee is avoided and a damaged knee recovers.

There is a need for an exoskeleton type brace that allows for additional flexibility in the brace and also the amount of pressure that is relieved from the knee.

SUMMARY OF THE INVENTION

The present invention provides an exoskeletal technology that delivers a medically prescriptive knee brace, which provides a mission adaptable brace by selecting a supportive range to protect the joints of the body (e.g., a knee) by unloading pack-weights so as to increase mobility and provide for support during activities (recuperation, athletic, etc.).

The present invention provides an unloader assembly to control load distribution about a joint by providing selectable levels of protection for all sports, extreme sports, military missions, prophylactic protection, rehabilitation and osteoarthritic applications.

In one embodiment of a exoskeletal structure suitable for supporting a knee joint, a knee brace configuration is disclosed that selectively unloads body weight from the (patella-femoral) knee joint using a VRB (Variable Resistant Beam) as a cantilever.

The VRB selective resistance cantilever provides a prescriptive range of lift to support and unload body weight from the knee joint.

The lift created by the locked VRB rotated selection gently separates and dynamically suspends the knee joint in proportion to loading.

The VRB cantilever additionally acts as a dynamic leaf spring to provide incremental reactive suspension to cushion the knee joint.

The VRB selectively and incrementally thereby prescriptively unloads or lifts body weight from the knee joint proportional to its resistance or fixed rotation.

The VRB incrementally and selectively unloads, lifts or separates the knee joint or the bones of the knee joint in the order of 1 mm (millimeter) to 3 mm and up to a maximum of 5 mm to provide pain relief for OsteoArthritic, Post Injury/Operative patients to reduce pain, increase healing and rehabilitation.

A VRB fixed at one or more points acts as a cantilever to selectively unload or lift; while simultaneously acting as a reactive leaf spring or dynamic suspension system for the knee, proportional to the loading of the resistance setting, thereby maintaining a set separation distance for the knee joint that is dynamically controlled.

A VRB cantilever with an elastomeric material acts as a selectable dynamic suspension system with a ‘secondary or artificial cartilage’ shock absorber to cushion or ‘catch’ the VRB from bottoming out under heaviest loading compression or flooring of the cantilever.

Additionally, a novel floating hinge is employed with a VRB cantilever to provide lift, suspension and separation to the knee joint.

Additionally, an elastomeric polymer or other shock absorbing energy returning material acts as a secondary cartilage in conjunction with a VRB. The shock absorbing material acts as a standalone and/or redundant back up to cushion and absorb impact loads that supersede the selected VRB suspension or mechanical limit of the VRB to support load.

The dynamically unloading knee brace provides prescriptive lift, suspension and separation for OsteoArthritc, Post operative, rehabilitative and prophylactic patients, as well as military field applications.

Dynamic Tension is achieved by selecting/setting resistance levels to impart corrective structural bias and or compensating support for a damaged joint.

According to the principles of the invention, redistribution of load and support of the patello-fermoral knee joint is applicable to provide flexibility of the joint for exercise activities such as walking, hiking, running and carrying additional pack weight.

In accordance with the principles of the invention, the brace system disclosed can also be used or integrated as a stand-alone modular unit or as part of an exoskeletal support system mechanically linked to a backpack, for example, and furthermore to a knee brace and the knee brace to an ankle support and ultimately to an orthotic or all terrain boot or footwear.

In accordance with the principles of the invention, the bushings act as a second knee cartilage. In accordance with the principles of the invention, the bushing or shock material may be a flexible material, such as rubber, elastomer or similar shock absorbing and energy releasing material.

In another aspect, the bushing may be of a mechanical construction.

A feature of an adjuster mechanism with indicia enables the wearer to ‘pre-load’ the VRB or bushing assembly by compressing the VRB against the vertical weight of the body. This provides lift or separation to the patello-fermoral joint to maximize comfort, brace fit and weight unloading to the knee joint for each individual's knee, injury or weakness, and pack weight, by incrementally vertically extending the floating hinge, lifting the upper leg/quadriceps.

The bushings have a range of Shore A durometers to adjust for ‘road feel’ or ergonomic comfort against body/pack weight. The bushing material may also be multi-layered to impart performance advantages a single material or mechanical construction could not provide.

In one aspect of the invention, the VRB or the bushing assembly's mechanical movement can be used as a battery recharging system using any device capable of capturing mechanical movement and converting the mechanical movement into electrical energy. For example, piezo-material or PvF2 (PolyVinylidene Fluoride 2) may be incorporated into the bushing assembly to create a battery recharging system.

In accordance with the principles of the invention, ergonomic, conformal and/or conical sectioned cup pads (hereinafter, pads) may be incorporated to assist the brace's retention of the quadriceps and calf muscles to ensure a positive positioning lock and enhance comfort. This is particular beneficial as muscle swelling and constriction occurs during hiking or extended periods of use.

In accordance with the principles of the invention, the conformal geometric/ergonomic plates are used to distribute load (i.e., the body's weight) over a greater surface area to increase comfort and hold or retain the brace in place. In addition, the conformal geometric plates may be perforated or breathable to allow perspiration to be drawn away from the skin.

In accordance with the principles of the invention, the plates can be ballistic protection for applications that are highly dangerous. For example, military and/or police operations.

In accordance with the principles of the invention, an optional knee pad may be incorporated to protect the knee cap or patella.

In accordance with the principles of the invention, the knee brace uses a floating hinge assembly to maximize shock absorption, energy return, comfort and natural knee movement.

In accordance with the principles of the invention, hyperextension selectable stops may be incorporated in order to protect the joint (e.g., knee) under load from hyper-extending.

In accordance with the principles of the invention, the exoskeleton brace disclosed provides for silent operation in an ultra-light weight configuration (aluminum, carbon fiber) that provides medial and lateral support (particular for the knee).

BRIEF DESCRIPTION OF THE DRAWINGS

The advantages, nature, and various additional features of the invention will appear more fully upon consideration of the illustrative embodiments to be described in detail in connection with the accompanying drawings wherein like reference numerals are used to identify like elements throughout the drawings:

FIGS. 1A-G represents exemplary-cross sectional views of different aspects of variable resistance beams (VRBs) in accordance with the principles of the invention wherein FIG. 1A represents a Type I Non-I-Beam configuration;

FIG. 1B represents a Type II I-Beam configuration;

FIG. 1C represents a Type III Dual I-Beam configuration;

FIG. 1D represents a Type IV Conical beam configuration;

FIG. 1E represents a Type V Ellipsoidal beam configuration;

FIG. 1F represents a Type VI Internal ‘I-beam’ configuration; and

FIG. 1G represents a Type VII Rectangular beam configuration.

FIG. 2A illustrates a perspective view of an exemplary embodiment of a knee brace in accordance with the principles of the invention.

FIG. 2B illustrates a side view of a polycyclic gear in accordance with the principles of the invention.

FIGS. 3A-3C illustrate an exemplary mechanism using VRB technology for controlling compression in the knee brace shown in FIG. 2.

FIGS. 4A-4D illustrate an exemplary configuration for controlling rotation of a VRB utilized in the knee brace shown in FIG. 2.

FIG. 5 illustrates a front view and a side view of a compression assembly in accordance with the principles of the invention.

FIG. 6 illustrates a cross-section view of a compression mechanism in accordance with the principles of the invention.

FIG. 7 illustrates a second exemplary embodiment of a knee brace in accordance with the principles of the invention.

FIGS. 8A-8E illustrate a second exemplary configuration for controlling rotation of a VRB utilized in the knee brace shown in FIG. 2.

FIGS. 9A and 9B illustrate perspective view of an exemplary exo skeleton body suit incorporating the knee brace shown in FIG. 2.

It is to be understood that the figures and descriptions of the present invention described herein have been simplified to illustrate the elements that are relevant for a clear understanding of the present invention, while eliminating, for purposes of clarity only, many other elements.

However, because these eliminated elements are well-known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements or the depiction of such elements is not provided herein. The disclosure herein is directed also to variations and modifications known to those skilled in the art.

DETAILED DESCRIPTION

FIGS. 1A-1G illustrates exemplary aspects of variable resistance beams (VRBs) in accordance with the principles of the invention. The VRBs, presented as resilient rods, beams or shafts may be composed of solid, semi-solid or hollow construction in accordance with embodiment the principles of the invention. The VRB technology produces variable resistances when orientated in a direction of x, y, z plane or combination of planes in 360 degrees of rotation, bending movement.

FIG. 1A represents a Type I Non-I-Beam configuration 105 that includes a circular cross-section having no outside or internal diameter geometry that would create an i-beam effect. Unlike a single static rod that is intended to produce a single measurement of static resistance, fulcrum adjustable resistance is relative and proportional to hand adjustable position as indicated by an indicia zone indicated by graphics, ergonomic ridges, structures, textures and or zones of color.

FIG. 1B represents a Type II I-Beam configuration 115 that includes one of: a static outside and internal diameter geometry or combination, thereof. The Type II I-Beam cross section geometry produces proportional adjustable resistance according to a rotated orientation creating a relationship between an orientation and a resistance.

FIG. 1C represents a Type III Dual I-Beam configuration 110 that includes inner and outer I-Beam tubes with inner and/or outer geometry or combination thereof to create variable I-beam resistance.

FIG. 1D represents a Type IV Conical beam configuration 120 that includes hollow, additive or subtractive wall geometry. Conical Beam cross section geometry produces proportional adjustable resistance according to a rotated orientation.

FIG. 1E represents a Type V Ellipsoidal beam configuration 125 that may be a solid, a semi-solid or a hollow beam with or without outside and/or internal diameter geometry or a combination, thereof along its major axis, thus, generating additional I-beam mechanics and/or subtractive, e.g., conical hollow, geometry along its minor axis. Ellipsoidal beam with a major axis that is wider than the minor axis with or without internal or external geometry along the major axis.

FIG. 1F represents a Type VI Internal ‘I-beam’ configuration 130 that includes one or more spines within a hollow cylindrical or conical shaft.

FIG. 1G represents a Type VII Rectangular beam configuration 135 that includes two sides wider than the remaining two sides.

Additionally, the resistance rods (VRBs) shown in FIGS. 1A-1G may include a plurality of graduated indicia that indicate bending resistance by measurement of a fulcrum distance from an anchored position to a hand position.

A VRB 100, which may be solid, semi-hollow or hollow, with or without geometrically created I-beam effect (i.e., Asymmetric geometry, spines) on the outside or interior diameter generates resistance depending on the axis of orientation and/or a fulcrum position has been described herein. A VRB 100, with incorporated I-beam geometry on the outside diameter, may allow for the dynamic adjustment of resistance of the device. An advantage of a device including a VRB's described herein may be-compact, lightweight and offer the ability to more easily and quickly change a desired level of resistance than is typically found in units using weights, rubber bands, bows or springs. By simple reposition or rotation of a VRB incorporated into the device, a desired selectable range of resistance level may be achieved. The VRB's 100 disclosed, herein, can provide resistance, depending on the orientation of the beam, to a bending direction. In addition, an exemplary device incorporating the VRB technology may vary the resistance provided to the user during rehabilitative exercise, without interrupting the exercise cycle. Additional beam resistance is achieved depending upon the relative orientation of the beam within a 180° degree hemisphere of movement relative to the user.

Hence, according to the principles of the invention, a progressive dynamic resistance may be achieved with a variation of the orientation of the beam or shaft shown herein.

In one aspect of the invention, rods with symmetrical cross sections vary their bending resistance by shortening and lengthening the arc length, from fulcrum to anchor point by hand position per indicia.

In another aspect of the invention, rods with asymmetrical cross sections may increase or decrease their bending resistance by rotation of the elongated orientation with respect to a bending force, while maintaining the same hand adjusted position or fulcrum length.

In one aspect of the invention, the VRB's 100 may be composed of thermoplastic polymers, especially high tenacity polymers, include the polyamide resins such as nylon; polyolefin, such as polyethylene, polypropylene, as well as their copolymers such as ethylene-propylene; polyesters, such as polyethylene terephthalate and the like; vinyl chloride polymers and the like, and polycarbonate resins, and other engineering thermoplastics such as ABS class or any composites using these resins or polymers. The thermoset resins include acrylic polymers, resole resins, epoxy polymers and the like.

Polymeric or composite materials may contain reinforcements that enhance the stiffness or flexure of the flexure resistance spine. Some reinforcements include fibers, such as fiberglass, metal, polymeric fibers, graphite fibers, carbon fibers, boron fibers and

Nano-composite additives, e.g. carbon nano-tubes, et al, to fill the molecular gaps, therefore strengthening the material.

Additional materials that the resistance rods or VRB's may also be composed of include high tensile aircraft aluminum and high carbon spring steel and/or high tensile strength to weight materials.

FIG. 2A illustrates a perspective view of an exemplary brace assembly 200, in the form of a knee brace, encompassing knee 202, in accordance with the principles of the invention.

Brace 200 comprises an upper frame 207 comprising an upper collar 205 and upper collar strap 205 a that encircles the thigh and connects to upper collar 205. Collar strap 205 a may be attached to upper collar 205 using a belt attachment or VELCO, for example. VELCO is a registered trademark of VELCO IndustriesBV LLC Netherlands. Brace 200 further comprises a lower frame 209 comprising a lower collar 206 and lower collar strap 206 a. In this illustrated example, the lower collar strap 206 a extends from a first side to a second side of lower collar 206 along the shin. Collar strap 206 a attaches to collar 206 using VELCO, for example.

Upper frame 207 further includes extensions 207 a that extend downward from the upper collar 205. Lower frame 209 similarly includes extensions 208 a that extend upward from lower collar 209. Although not shown, it would be appreciated that brace 200 includes two such extensions 207 a and 208 a; one on either side of knee 202. Extensions 207 a and 208 a represent attachment means that enable upper frame 207 and lower frame 209 to interact with one another.

A rotatable hinge 210, connected to the extensions 207 a and 208 a, joins the upper frame arm 207 and the lower frame arm 209, to allow rotation of the upper frame 207 with respect to the lower frame 209. Hinge 210 allows the contained joint (i.e., a knee 202) to bend and flex in a conventional manner. In one aspect of the invention, hinge 210 may be locked to retain a fixed orientation of the upper frame 207 with respect to the lower frame 209.

In this illustrated embodiment, a compression assembly 220 is incorporated into each of the extension arms 207 a or 208 a. Compression assembly 220 comprises an arm 225 extending from hinge 210, which is slideably engagable with a piston type assembly compression mechanism 227. Compression mechanism 227 includes an adjustable VRB and bushing, as will be discussed.

Arm 225 transmits vertical load into the compression mechanism 227, which is counterbalanced by the VRB resistance setting. The VRB acts as a cantilever providing reactive and dynamic suspension. The VRB, thus, provides prescriptive settings to lift or separate the patello-femoral knee joint incrementally, to minimize injury and maximize rehabilitative support and recovery.

FIG. 2B illustrates a side view of a polycyclic gear assembly in accordance with the principles of the invention.

In this illustrative example, extensions 207 a and 208 a engages gear 210 from upper and lower directions, as previously described. Incorporated in extension 208 a is compression assembly 220. Arm 225 slidably engages compression mechanism 227. Compression mechanism 227 includes VRB 100 and an elastomer material bushing 230. The elastomer material bushing 230 is positioned opposite a free end of arm 225 and VRB 100 is positioned between bushing 230 and free end of arm 225. VRB 100 and elastomer material 230 provide a resistive force to counterbalance vertical load through the polycyclic gear 210.

FIGS. 3A-3C illustrate exemplary examples of compression means 220, shown in FIG. 2, in different configurations of rigidity, in accordance with the principles of the invention.

FIG. 3A illustrated a front view (a) and a side view (b) of compression assembly 220 in a maximum rigidity state. In this illustrated example, hinge 210 is shown positioned in a substantially vertical orientation. However, it would be recognized that hinge 110 is bendable about a focal point 305.

Referring to FIG. 3A(a), in this illustrated embodiment, upper frame arm 207 a includes a rounded lower end 303 that is pivotable about a bearing 304. Similarly, lower frame arm 208 a includes a rounded upper end 306 that is pivotable about bearing 304. Focal point 305 is determined as the point between rounded lower end 303 and rounded upper end 306 and is the point that hinge 210 rotates about.

Compression assembly 220 is attached to bearing 304 (hinge 210) on a first end and to lower frame arm 208 a at a second end, in this illustrated case. Compression assembly 220 comprises a elastomer bushing 230 and a variable resistance beam (VRB) 100. VRB 100 extends at an angle offset from a perpendicular to bushing 230.

Further illustrated is bushing element 230 having a convex upper surface and a concave lower surface. VRB 100 is positioned on the upper surface of bushing 230, which enables VRB 100 to flex or bend as vertical loads are absorbed between the upper frame 207 to the lower frame 209.

The shape of bushing 230 further provides a shock absorbing back up and/or redundant cushioning system when the mechanical capacity of VRB 100 to absorb a downward load exceeds its mechanical ability to resist the load. In another aspect of the invention, bushing element 230 may be principally of a rectangular block in shape.

In this illustrated example, VRB 100 is positioned or oriented to achieve a maximum rigidity in absorbing loads transferred from the upper frame 207 to the lower frame 209 by VRB 100 being oriented in a maximum rigidity position. FIG. 3A(b) illustrates a cross-sectional view of VRB 100, wherein VRB 100 has an orientation having a largest diameter, and hence, a maximum degree of rigidity. The maximum force of VRB setting provides the highest patello-femoral LIFT/Separation and Dynamic (Load) Suspension for the knee.

FIG. 3B illustrates a front view (a) and a side view (b) of another configuration of compression assembly 220. As FIG. 3B is comparable to FIG. 3A, a description of those elements described in FIG. 3A that are similar to those elements shown in FIG. 3B need not be repeated.

As shown in FIG. 3B(a), VRB 100 is positioned in a middle resistance position. In this case, compression assembly 220 provides a medium (or mid-level) degree of rigidity to bending of VRB 100 as vertical loads are transferred from the upper frame 207 to the lower frame 209. FIG. 3B(b) illustrates a cross-sectional view of VRB 100, wherein VRB 100 has an orientation of a mid-level resistance, and hence, a mid-level degree of rigidity.

The middle force of VRB 100 setting provides for medium patello-femoral lift and/or Separation and Dynamic (Load) Suspension for the knee.

FIG. 3C illustrates a front view (a) and a side view (b) of still another configuration of compression assembly 210. As FIG. 3C is comparable to FIG. 3A, a description of those elements described in FIG. 3A and similar to those elements shown in FIG. 3C need not be repeated.

FIG. 3C(a) illustrates an example wherein VRB 100 is positioned in a minimum resistance mode. In this illustrative example, VRB 100 provides a minimum degree of rigidity to bending as loads are transferred from the upper frame 207 to the lower frame 209. FIG. 3C(b) illustrates a cross-sectional view of VRB 100, wherein VRB 100 has an orientation of a minimum diameter, and hence, a minimum degree of rigidity.

The minimum force or VRB setting provides the minimum patello-femoral lift and Separation and Dynamic (load) Suspension for knee.

A comparison of FIGS. 3A(b), 3B(b) and 3C(b) reveals that a diameter of VRB 100 traverses from a maximum diameter(maximum rigidity) to a minimum diameter (minimum rigidity) to change the degree of rigidity.

FIG. 4A illustrates a cross-section view of an exemplary configuration 410 of a head of VRB 100 that operates with a worm gear assembly in accordance with the principles of the invention.

In this illustrative configuration, VRB 100 (not shown) includes a substantially circular head 410 including gear 415 that, as will be discussed, allows VRB 100 to rotate from a minimum resistance position to a maximum resistance position, as will be described.

That is, VRB 100 rotates from a minimum resistance position corresponding to a minimum diameter (0°) to a maximum resistance position corresponding to a maximum diameter (90°).

However, it would be appreciated that the terms “minimum resistance” and “maximum resistance,” as used herein may similarly correspond to a maximum and minimum fixed rotation positions, without altering the scope of the invention. That is, the application of VRB 100 determines whether a minimum resistance position corresponds to a minimum resistance (or rigidity) or to a maximum resistance (or rigidity).

While the exemplary VRB head 410 is shown containing geared portion 415 along a partial circumference of VRB head 410, it would be recognized that geared portion 415 may extend around the entire circumference of VRB head 410. In such a configuration, the VRB 100 may rotate from a minimum resistance to maximum resistance and back to a minimum resistance as VRB 100 continues to rotate in a same direction.

FIG. 4B illustrates an exemplary rotation of VRB 100 as worm gear 430 is rotated against geared VRB head 410 including gear 415. Also illustrated is the orientation of VRB 100. In this case, VRB 100, which is illustrated as having an elliptical cross-section, is rotated from a maximum resistance position (FIG. 4B(a)) to a minimum resistance position (FIG. 4B(e)). Although VRB 100 is shown as being of a substantially elliptical shape, it would be recognized that any one of the VRBs cross-sectional view shown in FIGS. 1( b)-1(g) may be utilized without altering the scope of the invention.

FIG. 4C illustrates an enlarged view of worm gear 430 showing the engagement of gear 415 of head 410 of VRB 100. Worm gear 430 may include an adjustment means (such as an indentation 460, which captures an Allen key or Torx key, for example, that rotates worm gear 430.

As worm gear 430 rotates, the rotation of worm gear 430 is transferred to the gear 415 of head 415 such that VRB 100 may rotate, as shown in FIG. 4B.

FIG. 4C further illustrates a locking plate 420. Locking plate 420 retains worm gear 430 (and consequentially VRB 100) in a locked position.

FIG. 4D illustrates a top view of worm gear assembly 450 including worm gear 430 and locking plate 420. Further illustrated is screw (e.g. a set screw) 425 that alters the position of locking plate 420 with respect to worm gear 430.

In one aspect of the invention, as shown in FIG. 4D(a), assembly 450 includes a threaded opening 460, through which passes set screw 425 to engage locking plate 420. As set screw 425 is rotated in a first direction, locking plate 420 is moved toward worm gear 430. Locking plate 420 further includes a toothed surface opposite screw threads 435 of worm gear 430. As locking plate 420 advances towards worm gear 430, the toothed surface of plate 420 engages the screw threads 435 of worm gear 430. In this position, worm gear 430 is locked in position. Thus, the position of the VRB 100 is fixed at that position to which VRB 100 has been rotated by the rotation of worm gear 430.

In another aspect of the invention, FIG. 4D(b), screw 425 is rotated in a opposite direction, causing the toothed surface of locking plate 420 to withdraw from screw threads 435 of worm gear 430. In this illustrative embodiment, worm gear 430 is free to rotate.

As would be appreciated, a screw hole 466 and locking plate 420 are aligned with threaded screw hole 465, through which screw 425 is captured to locking plate 420. In this manner, locking plate 420 moves inward or outward along screw 425 as screw 425 is rotated. Screw hole 466 allows alteration of the position of locking plate 420 by an adjusting mechanism, such as an Allen Key, to rotate screw 425.

FIG. 4D(c) illustrates a top view of exemplary embodiment of the worm gear assembly 450 in accordance with the principles of the invention. In this exemplary embodiment, locking plate 420 engages screw threads 435 of worm gear 430. Also illustrated is VRB head 810 that engages screw threads 835 (through gear 415, not shown).

As previously discussed, rotation of worm gear 430 causes rotation of head 410, through engagement of gear 415), which in turn causes rotation of VRB 100. In this exemplary embodiment, plate 420 engages the screw thread 435 to prevent altering the position of VRB 100, as shown with regard to FIG. 4D(a). Thus, the orientation of VRB 100 is fixed.

FIG. 5 illustrates a front view (a) and a side view (b) of compression assembly 220.

Referring to FIG. 5( a), compression assembly 220 comprises an arm 225 that slideably engages compression mechanism 227 within housing 228. Also shown is VRB 100 and elastomer bushing 230. VRB 100 is rotated, as previously discussed, from a minimum rigidity position to a maximum rigidity position through gear 430.

As previously discussed, as the orientation of VRB 100 is altered from a minimum diameter to a maximum diameter with respect to bushing 230, the rigidity of VRB 100 in absorbing loads varies from a minimum to a maximum.

The positioning of VRB 100 creates a separation between bushing 230 and a lower end of arm 225. The separation varies as the orientation of VRB 100 changes from a minimum diameter position to a maximum diameter position (see FIGS. 3A-3C).

Also shown is indicia or marking (numbers 1-5) on a surface of housing 228. The indicia or markings provide an indication of the degree of rigidity of VRB 100.

FIG. 5( b) illustrates a side view of compression assembly 220. In this illustrated case, thread 435 of gear 430 are shown engaging gear 415 of VRB head 410.

Further illustrated is an Allen Key that may be used to engage indentation 460 to turn gear 430.

FIG. 6 illustrates an expanded view of compression mechanism 227 in accordance with the principles of the invention.

In this illustrative example, compression mechanism 227 includes VRB 100 oriented substantially perpendicular to elastomer material 230. Gear 430, as previously discussed, when turned changes the orientation of VRB 100 from a minimum rigidity position to a maximum rigidity position with respect to elastomer material 230.

Also shown is set screw 225 that alters the position of locking plate 430. As previously discussed, the position of locking plate 430 determines whether gear 430 is either free to rotate or retained in a fixed position.

FIG. 7 illustrates a second embodiment of the incorporation of a compression assembly 220 in accordance with the principles of the invention. In this illustrative example, compression assembly 220 is incorporated into upper attachment mechanism 207 a.

FIG. 7( a) illustrates a condition where a maximum rigidity position is obtained and FIG. 7( b) illustrates a condition wherein a minimum rigidity position is obtained. VRB 100 and bushing 230 are not illustrated. However, it would be understood that bushing 230 is opposite the unattached end of arm 225 and VRB 100 is positioned between bushing 230 and the unattached end of arm 225.

FIGS. 8A-8E illustrate a second exemplary configuration for controlling rotation of a VRB utilized in the knee brace shown in FIG. 2.

FIG. 8A illustrates a perspective view 800 of a second exemplary configuration of a control means 800 in accordance with the principles of the invention.

In this exemplary configuration, referred to herein after as “spline/socket”, which represents a manual, geared mechanism that selectively rotates a VRB (variable resistance beam) in controlled increments ranging from 0° to 90° while simultaneously controlling torque.

In this illustrated example, the spline/socket mechanical arrangement creates a secure, adjustable anchor point to prevent VRB 100 rotation.

As shown, the socket/spline 800 provides an adjustable locking system that secures a VRB 100 from rotation and therefore mechanically maintains a constant resistance or suspension.

As shown, VRB 100, which has been previously described includes a maximum diameter and a minimum diameter. VRB 100 further includes a fork or tongue 810 that is insertable into spline 820. Spline 820 is a substantially round, solid, rod including tongue or fork 825. Tongue or fork 825 engages (and matches) tongue or fork 810 of VRB 100.

Also shown is socket 830 into which spline 820 is inserted. Socket 830 contains fork 825 and tongue 810 in a manner such that as spline 820 is rotated, VRB 100 similarly rotated.

At a proximal end of socket 830 is shown grooves 835 and spline elements 845 formed between adjacent ones of grooves 835. In one aspect of the invention, The spacing of spline elements 845 (grooves 835), provides for a desired of locking rotation. For example, 16 spline elements 845 provide for 22.5° of incremental VRB rotation. (360°/16=22.5°).

In accordance with the principles of the invention, the VRB 100 plus spline 820 form an adjustable assembly, wherein the spline element 820 maybe pulled out by grasping spline head 840, rotating the spline element 820 and re-inserting the spline 820 into socket 830, to provide a higher or lower resistance or suspension level. This level of resistance is dependent upon the locked rotation angle of the VRB.

Also illustrated is faceplate 850. Faceplate 850 presents an indicia of the degree of turning of VRB 100.

As would be appreciated, tongues or forks 825 and 810 are sized so that they are always engaged, even when spline 820 is pulled out, turned and re-inserted into socket 830.

FIG. 8B illustrates a perspective view of spline 820. In this illustrative embodiment, spline 820 is a substantially cylindrical rod including at a first end fork 825 and a spline head 840 on a second end. Further illustrated are spline elements 845 positioned about the circumference of spline 820 between adjacent ones of grooves 835.

As shown a length of fork 825 is sufficiently greater than a length of spline elements 845 in order to prevent spline 820 from disengaging VRB 100 (not shown) when spline 820 is pulled from socket 830.

FIG. 8C illustrates a perspective view of a spline element 845 of spline 820 engaging grooves 832 of socket 830. In this illustrative example, socket 830 includes a plurality of grooves 832 and spline elements 834 between adjacent ones of grooves 832. Grooves 832 and spline element 834 of socket 830 match in number and width grooves 835 and spline elements 845 of spline 820.

As discussed, spline 820 may be withdrawn from socket 830, rotated and reinserted into socket 830. The rotated and reinserted spline 820 alters the position of the VRB 100 (not shown) such that a different level of rigidity of VRB 100 is achieved (see FIGS. 3A-3C). The engagement of spline elements 845 with grooves 832 lock and retain VRB 100 (not shown) in a desired position.

FIG. 8D illustrates a perspective view of a control mechanism 800 illustrating VRB 100 engaging fork 825 in spline 820 in accordance with the principles of the invention.

In this illustrative embodiment, VRB 100, which is shown having a rectangular cross-section, includes tongue 810 that may be inserting into fork 825 in order to provide a secure connection between tongue 810 and fork 825, as previously discussed.

Further illustrated is retaining ring 870. Retaining ring 870 represents a spring loaded mechanism that enables spline head 840 to be withdrawn from socket 830 by pushing spline head 840 into socket 830. The act of pushing spline head 840 into socket 830 disengages retaining ring 870 and the spring loaded mechanism forces spline head 840 to withdraw from socket 830. In one aspect of the invention, retaining ring 870 may be constructed of a springable material and shaped to operate as spring mechanism.

Further illustrated are pins 880, which when inserted into holes 885 provide a secure connection between fork 825 and tongue 810.

As would be appreciated holes 885 may be elongated in order to allow spline head 840 from being withdrawn a limited distance from socket 830. Hence, spline head 840 may not be totally withdrawn from socket 830 even if spline head 840 is inadvertently pushed in.

FIG. 8E illustrates a cross-sectional view of compression mechanism 220 in accordance with the secondary exemplary adjustment mechanism in accordance with the principles of the invention.

As shown c compression assembly 220 comprises an arm 225 that slideably engages a housing 228. Also shown is VRB 100, which is one element of compression mechanism 227, engaging a lower face of arm 225. Bushing 230 is not shown.

VRB 100 is rotated, in this exemplary embodiment, using a spline/socket mechanism shown in FIGS. 8A-8D, from a minimum rigidity position to a maximum rigidity position, as previously described. However, it would be appreciated that the worm gear mechanism illustrated in FIG. 4 may also be utilized without altering the scope of the invention.

Hence, in accordance with the principles of the invention, the VRB Cantilever piston compression assembly 220 illustrated mechanically acts as a piston arm that separates the upper arm 225 from the lower brace assembly 209 (see FIG. 2).

Arm 225 rides on top of the VRB 100 to transmit vertically and provide dynamic suspension/patello-femoral joint lift proportional to the VRB 100 selected resistance to bending.

The VRB resistance and therefore the patello-femoral vertical lift provided by arm 225 to the knee joint is a function of the selected locked rotated position of the VRB 100.

As previously discussed, as spline 820 is pulled out of socket 830, rotated and reinserted into socket 830, the orientation of VRB 100 is altered from a minimum degree of rigidity to a maximum degree of rigidity. Thus, allowing different levels of rigidity to be imparted to compression assembly 220.

Although the instant application has been described with regard to a knee brace, it would be appreciated that the assembly may be suitable for other joints. For example, the assembly may be incorporated into a brace suitable for use with an ankle, a wrist or an elbow.

In addition, it would be appreciated that the brace assembly described herein may be incorporated into a full body exoskeleton structure that allows for greater carrying capability as load is maintained through the exoskeleton.

FIG. 9A illustrates a front perspective view of a body exoskeleton in accordance with the principles of the invention.

The exoskeleton, shown in FIG. 9A delivers mission adaptable, reactive lower extremity/body brace support to protect the foot, ankle, knee and back, by maintaining bio-mechanic weight balance (i.e. dynamic suspension), optimizing body weight load distribution, and efficiently unloading pack weight, to minimize injury, maximize locomotion efficiency for field deployment.

As discussed, variable resistance technology applied to the joints of the body via interconnected or laddered orthotics (i.e. exoskeleton), correct bio-mechanical joint imbalances of the body under heavy loads for the foot, ankle, knee, back and the neck and thus enhance locomotion through running economy with comfort.

The exoskeleton support system 900 shown in FIG. 9A implements VRBs to act as adjustable resistance cantilevers to provide a selectable range of dynamic and reactive suspension to each joint, centering and correcting bio-mechanical joint imbalances of the body's joints (i.e., foot, ankle, back, knee) of the lower extremities under load, resulting in dynamic bio-mechanical support for bone, connective and musculature structures.

As shown, each foot, ankle, knee brace and back orthotic of the exoskeleton acts individually and in concert to dynamically and reactively support the body. The individual orthotics are connected by height adjustable energy return and or shock absorbing piston rods that further dissipate and cushion load from the body.

As shown in FIG. 9A, the foot orthosis 910 is connected via a flexible hinge 915 to ankle orthosis (AFO) 920 that is connected to the unloading knee brace 940 via a height adjustable energy return shock absorbing rod or piston 945 connected to the lower calf armature of the knee brace 940. Knee brace 940 has been described with regard to FIG. 2, for example, and the reader is directed to the description of FIG. 2 for further detail regarding adjustment of the knee brace 940 using VRB technology.

The top armature 950 of the knee brace 940 is connected to the lumbar armature 960 (i.e., a hip shelf for a rucksack) via height adjustable energy return shock absorbing rod or piston 965.

Specifically, the unloading knee brace 940 supports and unloads the patello-femoral knee joint in proportion to the loads placed upon the knee from the downward body and rucksack loads transmitted upon it from the rods or pistons that are connected to the lumbar armature shelf. The exoskeleton and its componentry, shown in FIG. 9A, act as a structural cage around the body to dynamically offload and support weight to assist human movement by maintaining bio-mechanic alignment.

The totality of the interconnected combined components provide an adjustable, dynamic, reactive and supportive exoskeleton structure 900 to protect the body from load and injury.

Additionally, potentiometer or linear joint (pressure or load) sensors relay information of degree and rate of joint bend to an onboard microcomputer. The enhanced biophysical sensor data provides intelligence to the physical health of the body and pro-active recommendations to prevent or mitigate injury.

In a powered exoskeleton, the enhanced biophysical sensor data augments, controls and amplifies wearer articulation response to move the hydraulic system in real time with the body. The resulting natural movement flow of the system allows persons to more intuitively run, walk, kneel, crawl, and squat.

FIG. 9B illustrates a rear perspective view of a body exo skeleton in accordance with the principles of the invention.

Methods of Sensing and Relaying Biomechanic Performance Data from VRB Deflection

In accordance with the principles of the invention, a method or physical, e.g., mechanical sensor or tensor, means of detecting and quantifying biomechanic performance data from VRB deflection in the brace assembly shown in FIGS. 2 and/or 9 may be incorporated in order to monitor in real time the health condition of individual joint operation and movement for stress, strain and loading cycles to prescriptively and pro-actively notify a wearer of potential injury.

In accordance with the principles of the invention, VRB deflection may be determined through the monitoring of the flexing shape of a VRB (Variable Resistance Beam) 100 or multiple VRBs as loads are dynamically applied, quantified and recorded with the wearer notified of loading conditions that would exceed the joints physical ability sustain normal operation without damage, e.g. repetitive strain

A few examples of physical sensors to measure and quantify joint stress, strain loading cycles are a Wheatstone bridges, potentiometers, temperature—pressure gauge, foils, piezo resistors, semiconductors, nano-particulates, conductive electroplating, diffraction grating, optical fiber, optical grid [Non-Intrusive Stress Measurement System—NSMS], wire, micro tubes, miniature WiFi transmitters, accelerometers and or other means to detect VRB flexure or movement of any kind.

Physical sensing occurs when VRB 100, or multiple VRBs, is deflected or flexed. As the physical shape of VRB 100 is deformed, an electrical resistance is changed and/or other measurement quality or physical parameter, e.g. optical, physical location or acceleration may be detected.

For example, the Wheatstone bridge determines a difference measurement, which can be extremely accurate. Variations on the Wheatstone bridge can be used to measure capacitance, inductance, impedance and other quantities.

Placement and locations of the biomenchanic sensors are typically bonded onto or along the surface length of a VRB, into a side channel and or internally through an interior diameter hole, bore and or extruded geometry to accept and hold the sensor.

In another aspect of the invention, a strain gauge may be incorporated into the knee brace shown in FIG. 2 or in the exoskeleton structure shown in FIG. 9, wherein advantage is taken of the physical property of electrical conductance and its dependence on the conductor's geometry. For example, when an electrical conductor is stretched within the limits of its elasticity without permanent deformation, the sensor will become narrower and longer. This changes or increases the electrical resistance along the sensors length or end to end.

When measuring electrical resistance of a strain gauge bonded to a VRB, the amount of applied stress may be inferred. As an example, another typical strain gauge arranges a long, thin conductive strip in a zig-zag pattern of parallel lines such that a small amount of stress in the direction of the orientation of the parallel lines results in a multiplicatively larger strain measurement over the effective length of the conductor surfaces in the array of conductive lines—and hence a multiplicatively larger change in resistance—than would be observed with a single straight-line conductive wire.

In addition, other methods of sensing VRB deflection, range from temperature (kinetic heating), piezo (milli-volt generation), optical sensing (diffraction grating), to miniature WiFi signaling physical location and or accelerometer chips.

In one aspect of the invention, all sensors are directly wired or connected to a physical circuit or by means of a wireless signal to an embedded printed circuit board (PCB) with processing algorithm, battery and transmitter. The on-board algorithm sends real time biomechanic data to a handheld, worn or remote receiver to alert the wearer to potential injury or current physical condition.

While there has been shown, described, and pointed out fundamental and novel features of the present invention as applied to preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the apparatus described, in the form and details of the devices disclosed, and in their operation, may be made by those skilled in the art without departing from the spirit of the present invention.

It is expressly intended that all combinations of those elements that perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Substitutions of elements from one described embodiment to another are also fully intended and contemplated.

In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. A single processor or other unit may fulfill the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage.

The term “comprises”, “comprising”, “includes”, “including”, “as”, “having”, or any other variation thereof, are intended to cover non-exclusive inclusions. For example, a process, method, article or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. In addition, unless expressly stated to the contrary, the term “or” refers to an inclusive “or” and not to an exclusive “or”. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present); A is false (or not present) and B is true (or present); and both A and B are true (or present).

Any reference signs in the claims should not be construed as limiting the scope of the claims or the invention described by the subject matter claimed. 

What is claimed is:
 1. An exoskeleton brace for supporting a joint, said brace comprising: an upper brace assembly positionable above said joint, said upper brace assembly including an upper attachment mechanism; a lower brace assembly positionable below said joint, said lower brace assembly including a lower attachment mechanism; a hinge positioned between a lower end of said upper attachment mechanism and a upper end of said lower attachment mechanism, said hinge allowing rotation of said upper brace assembly with respect to said lower brace assembly; a compression assembly comprising: a piston assembly incorporated into one of said upper attachment mechanism and said lower attachment mechanisms; an arm attached on a first end to said hinge and slidable within said piston assembly; a bushing positioned at an end of said piston assembly; and a variable resistance beam positioned between said bushing and said arm, said variable resistance beam having a minimum diameter substantially perpendicular to a maximum diameter; and a gear mechanism comprising: a gear having a known thread pitch, said gear engaging a geared head of said variable resistance beam having a comparable thread pitch, and an indentation incorporated into said gear, said gear mechanism altering an orientation of said variable resistance beam from said minimum diameter to said maximum diameter with respect to said bushing as said gear rotates.
 2. The exoskeleton brace as claimed in claim 1, said gear mechanism further comprising: a locking plate, said locking plate slidably engaging said thread pitch of said gear.
 3. The exoskeleton brace as claimed in claim 1, wherein a cross-sectional view of said variable resistance beam comprises one: rectangular, elliptical, sculptured, internal spine, and external spine.
 4. The exoskeleton brace as claimed in claim 1, wherein said variable resistance beam is composed of a material selected from a group consisting of: plastics, thermoplastic polymers, copolymers, polyesters, vinyl chloride polymers and polycarbonate resin, metals, and re-enforced plastics.
 5. The exoskeleton brace as claimed in claim 1, wherein said bushing is an elastomer material.
 6. The exoskeleton brace as claimed in claim 1, wherein said bushing comprises: an upper surface; and a lower surface, said upper surface contacting said variable resistance beam.
 7. The exoskeleton brace as claimed in claim 1, wherein said bushing comprising: a rectangular block shape
 8. The exoskeleton brace as claimed in claim 1, wherein said geared head of said variable resistance beam includes a gear along a portion of said head.
 9. The exoskeleton brace as claimed in claim 1, further comprising: an indicia, said indicia representative of said VRB rotation.
 10. The exoskeleton brace as claimed in claim 1, wherein said gear is a worm gear.
 11. A knee brace supporting a knee comprising: a thigh attachment member including an upper extension; a calf attachment member including a lower extension; a hinge, on each side of said knee, positioned between said upper extension on a first end and said lower extension on a second end, a compression assembly incorporated into one of said upper extension and said lower extension, said compression assembly comprising: an arm attached to said hinge; and an housing, said arm being slidable in said housing, said housing comprising: a bushing opposite said arm; and a variable resistance beam positioned between the bushing and the arm, said variable resistance beam position at an angle offset from a horizontal above the bushing, said variable resistance beam comprising a major axis and a minor axis; a gear assembly comprising: a threaded gear engaging a geared substantially circular head of said variable resistance beam, said gear rotatable to change an orientation of said variable resistance beam to create a variable separation between said bushing and said arm; and a movable locking plate engageable with said gear.
 12. The knee brace as claimed in claim 11, wherein a cross-sectional view of said variable resistance beam comprises one: rectangular, elliptical, sculptured, internal spine, and external spine
 13. The knee brace as claimed in claim 11, wherein said bushing comprises: a concave upper surface; and a convex lower surface, said concave upper surface contacting said variable resistance beam.
 14. The knee brace as claimed in claim 11, wherein said variable resistance beam is composed of a material selected from a group consisting of: plastics, thermoplastic polymers, copolymers, polyesters, vinyl chloride polymers and polycarbonate resin, metals, re-enforced plastics and nano-reinforced plastics.
 15. The knee brace as claimed in claim 11, wherein said bushing is composed of an elastomer material.
 16. The knee brace as claimed in claim 11, wherein said geared head of said variable resistance beam includes a gear along a portion of said head.
 17. A brace assembly comprising: a first collar, said first collar comprising first and second extensions extending from said first collar; a second collar, said second collar comprising first and second extension extending from said second collar; a first hinge attached to said first extension of said first collar and said first extension of said second collar; a second hinge attached to said second extension of said first collar and said second extension of said second collar; a compression assembly incorporated into said first extension and said second extension of one of said first collar and said second collar on a first end and a corresponding one of said first hinge and said second hinge, each of said compression assembly comprising: an arm attached to a corresponding one of said first hinge and said second hinge, said arm slidably engaging a housing incorporated into corresponding first extension and second extension; a bushing within said housing; and a variable resistance beam, oriented substantially perpendicular to said bushing between an upper surface of said bushing and a free end of said arm.
 18. The brace assembly of claim 17, wherein said variable resistance beam having a cross section view selected from a group consisting of: rectangular, elliptical, and elongated.
 19. The brace assembly of claim 17, further comprising: means for altering an axis of said variable resistance beam with respect to said bushing.
 20. The brace assembly of claim 19, wherein said means for altering an axis of variable resistance beam comprises: a gear assembly engaging a geared head of said variable resistance beam.
 21. The brace assembly of claim 19, wherein said means for altering an axis of variable resistance beam comprise: a spline/socket mechanism. 